Method and apparatus for setting and integrating home automation grid or network with electrical grid

ABSTRACT

A method and apparatus for setting and integrating home automation grid with an electrical grid of a residence and commercial unit by structurally connecting intelligent support boxes of electrical wiring devices comprising AC outlet, switch, relay, hybrid switch-relay and hybrid switch of the wiring device attached into the intelligent support box. The box including intelligent control and communication circuits including RF, RFID, optical via plastic optical fiber and IR in line of sight for communicating commands and control including power consumption reporting from every outlet and switch. The power outlets include accesses for introduction of RFID sensor or optical sensor for identifying the appliance or the load powered via the outlet and communicating with the load or appliance by variety of signal used in the home automation grid and protocols including optical via cascading optical cable grid.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention is related to electrical automation devices includingswitches, relays and AC outlets for manual and remote operation ofappliances including the reporting of power consumption in residencesand other buildings.

2. Description of the Prior Art

Switches, relays and AC outlets for powering and/or switching on-offelectrical appliances such as water boiler, air conditioners, heaters,lights and any other electrical equipment and appliances in residences,offices, public building, businesses, restaurants and factories are verywell known. The well known relay devices for home automation arecommonly installed in the main or a sub electrical cabinet of a givenpremises. The installed relays are operated via bus lines, RF, or bycontrol signal propagated via the AC power line.

The costs of the prior known automation devices and relays includingtheir installation are very high because the electrical wiring must bechanged from its standard commonly applied wiring systems, in which theelectrical power is fed via the commonly installed switches in theelectrical wall boxes. This is in clear contrast to the electricaldirect feed from the main or sub electrical cabinet via the relays. Forcontrolling the relays in the electrical cabinets, the commonly usedstandard switches are replaced by control switches, propagatingelectrical signals, RF signals, AC power line signals and in someinstances IR signals in open air to reach and operate the relay'scontrol circuits in the electrical cabinets.

Such fundamental basic change in the structured electrical systemsbecame too complex, costly and moreover the complexity is the cause forserious repeated malfunctions of the installed electrical automationsystems. Further, the known home automation devices do not report thepower consumed by the individual electrical appliances and do notprovide usable data for reporting statistics to the home owners, nor tothe yet to be born “smart grid”.

The U.S. Pat. No. 7,649,727 introduced a new concept whereby single poledual throw (SPDT) relay connected to a commonly used SPDT switch or dualpoles dual throw (DPDT) switch enabling to switch the electricalappliances or lights manually via the commonly installed switch andremotely via the home automation controller. The SPDT and DPDT switchesare known also as two way or four way switch respectively.

Further, the U.S. Pat. Nos. 7,639,907, 7,864,500, 7,973,647, 8,041,221,8,148,921, 8,170,722, 8,175,463, 8,269,376, 8,331,794, 8,331,795,8,340,527, 8,344,668, 8,384,249, 8,441,824, 8,442,792, US publication2013/0183043 and U.S. patent application Ser. Nos. 14/045,877,14/093,966 and 14/143,133 disclose home automation controls,connections, switches and relays for operating electrical appliance viaadd-on devices such as the SPDT and DPDT relays or current drain sensorsand via hybrid switches including hybrid switches operated viamechanically latching relays.

The referenced US patents further disclose in details the reporting ofthe power consumed by the appliances through the relays or through ACoutlets and plugs or through the current drain adaptors. The currentdrain or power consumption reports are communicated via optical signalsthrough plastic optical fiber cables known as POF or lightguide, via IRor RF in open air, and via electrical signals through bus lines or othernetworks directly or via command convertors.

The above listed US patents and many pending applications in othercountries disclose an add on or a combination of separate SPDT or DPDTswitches and/or power sockets and/or current sensing adaptorcombinations, which all teach substantially advanced residence and otherbuilding automation.

Yet, there is a need for yet further simplified automation devicecomprising a combination of a switch and a relay including the sensing,calculation and reporting power consumption circuits, structured withinthe sizes and shapes of current day commonly used AC switches at a lowercost than current day automation devices and providing furtherinstallation ease and simplicity.

SUMMARY OF INVENTION

The main object of the present invention therefore is to provide smallsize combination of manual switches, hybrid switches, integrated switchrelay and AC outlets and sockets, each constructed to be an “attachabledevice” in a size preferably smaller than a commonly used mechanical ACswitch or AC outlet, referred to hereafter as a “standard AC switch oroutlet”, that is mounted into a standard electrical wall box, such asthe known 2×4″ or 4×4″ wall boxes in the US, or such as 60 mm roundEuropean electrical wall box or other rectangular electrical boxes asused in Europe for installing plurality of standard AC switches and ACoutlet/sockets.

Another object of the present invention is to integrate a control,command and communication circuit with at least one or plurality ofhybrid switches, relays and switches, including SPDT or DPDT switchesand relays each with individual current sensors for calculating andreporting individual power consumption via a calculation circuit andprogram.

The term “hybrid switch” refers to hereafter and in the claims to one ofrelay/switch combination and mechanical latching relays used forelectrical automation system disclosed in the referenced US patents andpatent application, including the controlling of the hybrid switch andfor reporting the power consumed via the hybrid switch through a videointerphone system or a shopping terminal and/or via a dedicatedautomation controller or control station.

The video interphones are disclosed in U.S. Pat. Nos. 5,923,363,6,603,842 and 6,940,957 the shopping terminal is disclosed in U.S. Pat.Nos. 7,461,012, 8,117,076 and 8,489,469.

Another problem affecting the electrical power consumption is the use ofmany relays, each consumes power for self-operating and control. Manyrelays installed in a residence or in a shop, or in a factory, or inpublic facilities persistently drain current, each consumes small orlimited power. However, the overall consumed power will be substantialwhen many such relays and automation system circuits are installed.

Reducing the individual relay consumption and the number of controlcircuits is needed to reducing the overall power consumption.

Latching power relays, using dual magnetized armatures or poles or otherstructured magnetic elements are expensive and requiring complexcircuitry and programming to control. Moreover, most of the magneticlatching relays can provide for limited current drain, because of thelimited magnetic power for tightly engaging the relay contacts, such asmaximum 8A which is below the commonly used AC switches for lighting asan example that are provided with 15A-16A as standard.

The well known latching relays are operated by a short power pulse andlock or latch into on or off (SPST) or change over state using SPDT orDPDT relays. After engaging the contacts the coil is no longer consumingpower and the poles are magnetically latched into position. As themagnetic power is declining over time, this will eventually deterioratethe pole's contacts surface and the relay will eventually fail.

A small power relay for integration into an hybrid switch, such asdisclosed in U.S. patent application Ser. Nos. 14/045,877, 14/093,966and 14/143,133 filed on Oct. 4, 2013, Dec. 2, 2013 and Dec. 30, 2013respectively that can be latched into position via a mechanical latchingstructure.

Another practical objective attained by the present invention is toprovide the hybrid switch with a structure that can be fitted withdifferent key levers and the freedom to select any from a wide varietyof levers and decorative covers and frames including variety of designand colors that are available and are being regularly introduced to theconstruction/electrical industry by the different switchesmanufacturers. Hence, this invention of the intelligent support boxsolves the difficulties experienced to match such wide range ofavailable AC switch designs, AC outlets design, their panel colors anddecorations.

Three types of switches for AC appliances and light fixture are commonlyused; a single pole-single throw (SPST) and a single pole-double throw(SPDT) switch. The SPST switch is a basic on-off switch and the SPDT isa change over switch. The SPDT switches are used for on-off switching ofa given appliance such as light fixture from two separate positions,such as from the two entrances of the same hall or a room.

In instances were three or more switches are needed to switch on-off thesame light fixture of a given hall or room, another type of dualpole-dual throw (DPDT) switches are used. The DPDT switch or pluralityof switches are connected in a given straight-cross configuration inbetween the two SPDT switches described above. The DPDT switches arealso known as “reversing” switches.

It is well known that two SPDT switches including the one or morereversing or cross-straight DPDT switches connected in a continuoustraveler configuration provide for each individual switch to operate onits own, regardless of the other switches status. Therefore any of theswitches that are connected in such SPDT and/or DPDT setup configurationwill switch on and off the light fixture irrespective of the otherconnected switches status. This further means that there is no specificon or off position for any of the connected switches or their levers,and the switching on or off is achieved by pushing the switch lever toits opposite position, or by pushing a push on-push off key.

Accordingly the object of the present invention is to provide theintelligent box with facilities to connect hybrid switch comprising anSPDT relay to an SPDT or DPDT switch that are connected for operating alight fixture or other electrical appliance, thereby maintaining theoperation via a “commonly used” manual switch and provide remoteswitching via the SPDT relay of the hybrid switch, or for operating thelight fixture via a chain of DPDT and SPDT switches as commonly used andprovide the same remote switching via the SPDT relay of the hybridswitch.

Another object of the present invention is to provide for connectingDPDT relay for remotely switching on-off light fixture or otherelectrical appliance that are connected to manual SPDT switches and to amore comprehensive switching setup that includes two SPDT and one ormore DPDT switches.

Chain connected SPDT and DPDT switches of the electrical system of theprior art made it necessary to identify the on-off status of theappliance such as light fixture for providing accurate control command,and such data pertaining to a given circuit transmitted to thecontroller must include current drain, power consumption or statussensing data as disclosed in the U.S. Pat. No. 8,269,376.

For this reason the other important object of the present invention isthe introduction of individual AC current sensor for each hybrid switchand AC outlet for identifying when the appliance is switched on and forprocessing data pertaining the power consumed by the appliance.

This is achieved by the introduction of a current sensor such astoroidal or a structured current transformer, or by a low ohmic metalalloy structure calculated to introduce a serial resistor of mili ohmunits connected in line with the AC live line of each individual switchand outlet, or by a magnetic hall sensor or any other low ohmic resistoror other element that can generate output signal corresponding to thelevel of the current drain through the live AC terminal of the givenhybrid switch, mechanical switch, relay and AC outlet integrated intothe intelligent support box of the present invention for communicatingpower consumption data with the home automation grid or network.

The output signal level of the current sensor is measured in mV unitsand is amplified to a level that can be processed by a CPU, with both anamplifier and the CPU are included in the intelligent support box forgenerating the drained current data, or the power consumed data, or theon-off status data and combinations thereof.

The intelligent support box of the present invention includes atransceiver for receiving commands to operate the hybrid switches or therelays installed into the box and for transmitting the data pertainingthe status of each connected appliance, the power consumed or thecurrent drain. The data is processed on the basis of the identifiedappliance, the level of the AC current drained through the currentsensor timed versus the voltage reference throughout the sinusoidalcurve of the AC power as measured by the CPU.

The received commands and the transmitted data are fed via acommunication network selected from a group consisting of wired networksuch as bus line, optical network or grid of optical cables, two way IRnetwork, RF wireless network and combinations thereof.

The transceiver of the intelligent support box communicates at least oneway of two way or bidirectional signals with the home automationcontroller, the video interphone or the shopping terminal. Thetransceiver and the CPU are programmed to respond to a power-on commandto the connected appliance with a reply that a power-on is acknowledged,or respond to an inquiry pertaining status, current drain and the powerconsumed by the appliance, thereby updating the home automationcontroller, or said video interphone or the shopping terminal describedin above referenced US patents, or respond with “off status” if thecommand was to switch off the appliance.

The reference to home automation controller hereafter is to a displaydevice with control keys, touch icons or touch screen and circuitssimilar to the video interphone and/or the shopping terminal disclosedin the applications and the US patents referred to above.

The terms “hybrid switch” and “hybrid switch relay” hereafter and in theclaims refers to the integrated combinations selected from a group ofSPDT relay, DPDT relay, DPDT reversing relay with SPDT switch, DPDTswitch and reversing DPDT switch of the preferred embodiment of thepresent invention.

The term “SPDT hybrid switch” refers to a stand-alone switching devicefor operating a given load manually and remotely.

The term “DPDT hybrid switch” refers to a stand-alone switching devicewith dual poles. It is used for example for operating a load in a wet orhumid environment, such as bath room or laundry area for switchingmanually and remotely the two poles one pole feeding the live AC and theother the neutral AC.

The terms “reversing hybrid switch”, “crossing hybrid switch” and“reversing DPDT hybrid switch” refer to a switching device for a givenload that is switched on-off via the reversing hybrid switch and via atleast one SPDT switch and/or via an intermediate n DPDT switches allconnected in a cascaded chain of dual traveler lines, with each of theconnected switches can operate the given load, or switch it on-off.

A major objective of the present invention is to introduce AC outletsstructured to be a plug-in device similar to the disclosed self-lockingstructure of the hybrid switch into a counter and complementingstructure of the intelligent support box comprising at least one of anoptical transceiver and RFID antenna for communicating optical or RFIDsignal with a complementary plugs including optical transceiver, RFIDantenna or an associated RFID antenna.

The optical transceiver and/or RFID antenna and/or identificationsetting selector are introduced into an opening or a cavity in thestructured plugged-in AC outlets via a fit protruding structure of theinner cover of the intelligent support box of the present inventionwhich is further explained in the description of the preferredembodiment.

The term “springy element” of the hybrid switch refers to a bendingand/or flexing pole, or to a pole that is structured for providingspring like contact, or to a pole comprising a spring, or to a poledriven by a spring, or to an electrical contact driven by a spring, orto a contact comprising a spring, or to a contact structured into aspring like element and any combinations of a spring or structureassociated with a pole and the contacts of a latching relay. A typicalspringy pole can be a pole of a micro switch, or similar structuredmulti elements pole of the different known micro switches.

The terms “pin” or “pins” hereafter and in the claims refer to aconnector pin, such as commonly associated with a connector, for example8 pin plug and socket. The pin or pins referred to hereafter cover lowor high current pin having flat, round or any other shape or structurefor joining a support box to wiring devices such as an outlet and aswitch.

The term “joint” and “joints” hereafter and in the claims refer to a pinand to a socket or a receptacle that are jointly connecting thecomplementing or reciprocating pin and receptacle or socket forinterconnecting AC wiring devices with a support box.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and features of the present inventionwill become apparent from the following description of the preferredembodiments of the invention with reference to the accompanyingdrawings, in which:

FIGS. 1A˜1C are perspective illustrations of the prior art showing theinstallation and connections of the wiring devices of the prior artdisclosed by the referenced US patents and the actual use of such wiringdevices as experienced in the field.

FIGS. 2A˜2D are perspective illustrations of the intelligent supportingboxes for the electrical power outlets and the SPDT switch-relaycombinations or the hybrid switches of the preferred embodiment of thepresent invention;

FIGS. 3A˜3E are perspective illustrations showing the rear or back viewsof the boxes, the power outlets and the hybrid switch or theswitch-relay combinations of FIGS. 1A˜1D including the wiring terminals;

FIGS. 4A˜4C are perspective illustrations showing the expandedintelligent boxes of the present invention shown in FIGS. 1A˜1D foraccommodating n number of electrical power outlets and hybrid switches,or switch-relay combinations of the present invention;

FIGS. 5A˜5C are perspective illustrations for showing the versatility ofthe intelligent boxes of the preferred embodiment that can be mountedvertically for supporting modified power outlets shown in FIGS. 1B, 1D,2A, 2C, 2E and 3C structured for mounting into vertical column boxes;

FIGS. 6A˜6E are perspective illustrations showing the non-limitingversatility of the intelligent boxes of the present invention forsupporting a whole range of AC outlets as used in the differentcountries or regions of the world;

FIGS. 7A and 7B are perspective views and illustrations showing theintroduction of RFID tags onto different power plugs for identifying theload or the appliance connected to a corresponding power outletsupported by the intelligent boxes of the preferred embodiment;

FIGS. 7C and 7D are perspective views and illustrations showing theintroduction of optoports or optical transceivers for controlling theappliances and reporting the power consumed via the power plugs and thepower outlets supported by the intelligent box of the preferredembodiment of the present invention;

FIG. 8A is a front view drawing of the intelligent box showing the powerand ground connecting terminals including attachment sockets for theintelligent sensors or setting selector for identifying the type ofappliance connected to the power outlet of the preferred embodiment;

FIGS. 8B and 8C are top and cut views of the socket and of theselectable/replaceable intelligent sensor attachment particulars;

FIG. 8D is a top view of the contact positioning for the differentintelligent sensors or rotary selectors for identifying the connectedload or appliance needed for reporting the power consumption via thepower outlet of the preferred embodiment;

FIGS. 8E and 8F are perspective views of the intelligent box and theassembling of the selectable/replaceable intelligent sensor includingthe rotary selectors of the preferred embodiments of the presentinvention for identifying the load or the appliance;

FIG. 9A is a perspective illustration showing the loading of data intothe intelligent supporting box via the socket of the intelligent sensorof the preferred embodiment;

FIGS. 9B and 9C are top views of the internal receptacles as providedfor the different three and four gang boxes models;

FIG. 10A is a top view illustration including the ground connecting barfor the power outlets of the preferred embodiment;

FIGS. 10B and 10C are rear views of the self-locking terminals of thedifferent three and four gang model boxes of the present invention;

FIGS. 11A˜11C are perspective views of the structure of the self-lockingterminals and the receptacles of the three, four and six gang boxes,including the low ohmic metal alloy structure for measuring the currentdrain of each outlet and hybrid switch of the present invention;

FIG. 12 is an electric block diagram covering the electricalinterconnections of the pins, receptacles and terminals of theintelligent box, including the RFID, RF and optical communicationcircuits, the CPU, the memory and current sensing circuits for thereporting power consumption of the preferred embodiment of the presentinvention;

FIG. 13 is an electric graph showing the current versus the voltagephase shifts and the measuring principle for the power consumptioncalculations;

FIGS. 14A and 14B show cut and perspective views of the SPDT hybridswitch-relay combination for introduction into the intelligent supportbox of the present invention;

FIG. 14C show perspective views of a DPDT hybrid switch-relay forintroduction into the intelligent support of the present invention;

FIG. 14D shows a perspective view of a micro switch with a latching keyfor introduction into the intelligent support box of the presentinvention;

FIG. 14E shows a perspective view of the hybrid switch for introductioninto the intelligent support box of the preferred embodiment of thepresent invention;

FIG. 15 is an electrical connection and control network showing theinterconnections of a typical residence in a high rise building with anautomation control throughout and power consumption reporting of thepreferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIGS. 1A˜1C show wiring connections and the assembly or installation ofswitches and power outlets of the prior art disclosed by the recitedU.S. Pat. Nos. 7,639,907, 7,649,727, 7,864,500, 7,973,647, 8,041,221,8,148,921, 8,170,722, 8,175,463, 8,269,376, 8,331,794, 8,331,795,8,340,527, 8,344,668, 8,384,249, 8,442,792, 8,594,965, 8,638,087 and8,639,465 and corresponding patents in other countries and regions.

Each recited power outlet comprising intelligent circuit for measuring,calculating and reporting the power consumed through it by a load orappliance. The recited SPDT or DPDT switches connected to SPDT relayeach comprising a relay control and communication circuit for operatinga load via the relay and for reporting the current drain or the powerconsumed by the load or appliance.

The communication circuits for control and reporting the powerconsumption is selected from a group comprising optical via fiber opticcable or lightguide, RF, IR in line of sight and electrical signal viabus line.

The control, command and communication of the prior art are shown inFIGS. 1A and 1C to be optical signals propagated via cascadinglightguide. The term lightguide is a term used for plastic optical fibercable, known also as POF, however other optical fiber cables and RFsignals can be used for the control and communication of the prior art.

FIG. 2A shows an intelligent supporting box 3H for accommodating threeelectrical hybrid switches H1˜H3, each comprising self-locking convexes15 and stoppers 5A for locking into the indentations 15A and 5 of theboxes, when a hybrid switch H is inserted into position within the box3H.

The box 3H and 1H+1S shown in FIG. 1B is mounted into a three gangelectrical wall box, such as shown in FIG. 1A of the prior art or suchas the known 4″×2″ US wall box and are attached by screws, shown in FIG.1A of the prior art to the wall box via the mounting holes 23.

The other intelligent boxes shown in FIGS. 2C and 2D are each mountedinto a four gang elongated rectangular electrical wall box, such as usedin Europe, having variety of lengths and widths. All the different knownwall boxes, the surrounding supporting frames 20F, the frame of thepresent intelligent box, the shown hybrid switches H and the shown poweroutlets S surrounds are covered by an installed decorative cover of theprior art shown in FIGS. 1A and 1B.

The decorative covers are adjustable to be flat with the wall surface bytheir self-locking studs or locks inserted through the cover lockingsockets 23, shown on the four corners of the frames 20F of theintelligent boxes of FIGS. 2A˜2D.

The shown frame 20F is well known and is commonly used as a supportingframe for locking into place wiring devices known as mechanical switchesused for lights and the commonly used power outlets, all connected attheir rears or sides to the electrical power wires via screws orself-locking electrical terminals, shown in the prior art of FIGS.1A˜1C.

Accordingly, one obvious difference between the illustrated boxes inFIGS. 2A˜2D and the prior art supporting frames of FIGS. 1A˜1C are theback or the rear of the intelligent boxes, including all the pins,receptacles and terminals for self-locking wiring devices. The otherdifferences are the back surfaces and structure of the hybrid switch andpower outlet that are structure and shown in FIG. 3A to be without thewell known wire terminals, ready for self-locking action by a simpleinsertion into the intelligent box of the present invention.

The hybrid switch H is shown in FIG. 3A to include live line pin 1L,load pin 1LD, coil pin CO and key indicator access K1 for multi colorsLED light. The AC or power outlet of FIG. 3A is shown to include live ACpin 1L, neutral AC line pin 1N, receptacle entry 2G for the ground orearth pin 1G and an opening 10R for an intelligent sensor or rotaryselector for identifying the load or the appliance being connected orplugged into the AC outlet.

By the above it is clear that the structural differences between theprior art wiring devices supporting frames, switches and outlets and theintelligent supporting boxes with the plugged-in hybrid switches andpower outlets demonstrate a clear fundamental structural difference,while the assembled wiring devices may be perceived from the “outervisible side” that the switches and outlet are similar.

Each of the mechanical switches and outlets of the prior art isindividually connected to the power wires accessed through the wall boxand therefore require extensive work for connecting the many wires tothe plurality of outlets and switches confined to within the wall box.In contrast the intelligent box connects to few wires and the hybridswitches including the power outlets of the present invention areplugged-in through the front or the frame 20F and into the receptacles2L, 2LD and 2N and to GND pin 1G into the receptacle 2G of the poweroutlet.

The substantially reduced number of power and ground wires are connectedthrough self-locking terminals surrounding the back cover of theintelligent box shown in FIGS. 1A˜5D. This arrangement reduces thenumber of wire connections, the time it takes to mount each individualswitch and outlets, and thereby reducing significantly the errors inconnecting the individual power wires.

This by itself introduces a substantial improvement to the prior artstructure and facilities and this is without considering theintelligence and automation added by the present invention to theelectrical wiring and system of a given residence or business building.The system as will be explained below provides a comprehensiveelectrical automation control including the reporting of the powerconsumption from each and every power switch and outlet that aredetailed below.

Further, the intelligent boxes of the present invention with noautomation control simplify the prior art of electrical installations.It becomes clear that the cost of the mechanical SPDT or SPST switch andthe power outlet of the prior art shown in FIG. 1A can be reduced byeliminating the wire terminals and by replacing the wire terminals withplug-in pins 1L, 1N, 1LD and a receptacle 2G.

The other cost saving is the support frame that is modified ortransformed into support box to include terminals 1G and receptacles 2L,2N and 2LD as shown in FIGS. 2A˜9C. All above is without theintroduction of the intelligent circuits and other elements discussedlater below.

The shown pins 1, receptacles 2, stoppers 5A, indentations 5, convexes15 and the concaves 15A in FIGS. 2A˜11C are in fact a group of jointsfor the electrical lines and mechanical structures for interlocking thewiring devices to the support box. The pin and the receptacles can bereversed such that a pin is a receptacle and a receptacle is a pinproviding that they are complementary to each other. Same applies to theconvexes, concaves, stopper and indentations, they can be reversed butremaining complementary to each other.

Moreover the stopper and the convex can be one structure and not two.The shown convexes, concaves, stoppers and indentations are anillustration of locking structures that can be made in many differentshapes, forms and sizes.

Accordingly, the present invention will be meaningful, effective andsubstantially reduce the time and cost of installing the electricalwiring devices of the prior art. All this is achieved by modifying theinstallation of the electrical wiring devices sockets, the lightswitches and the support frames of the prior art and apply the plug-ininstallation methods recited and shown above.

The intelligent support boxes can be expanded to accommodate n number ofhybrid switches and power outlets as shown in FIGS. 4A˜6E. FIGS. 4A, 4Band 4C show the intelligent boxes 6H, 2H+2S and 3S, all are configuredas 6 gang box, wherein a “gang” is the width size of the hybrid switch Hwhich is similar to the width size of the prior art mechanical switches,ranging to be between 22˜24 mm, or less than 1″ width. However anyvariation of the switch sizes can be accommodated by the intelligentsupport boxes of the present invention.

The power outlets, be it the SM used in Israel and the middle easterncountries plugs and socket, or the SG type used in Germany and overallin Europe, or the SF type which is a French version of the Europeanplugs and sockets, including Japan and the US power outlets for two pinplugs SU, the US and Japan power outlets for three pin plugs SUG, thepower outlets for Australian type plug SA that are also used in Chinaand the UK and Hong Kong outlets for British standard plug SB are allaccommodated in dual gang sizes.

For example the hybrid switch H width size is 23.5 mm the width of thepower outlet will be about 46-47 mm. All the different power outlets areshown in FIGS. 4C, 5A, 5B and 6A to 6D. The power plug for two pin USand Japan plugs are accommodated in a single gang size.

It is important to note that the power outlets are also structured forvertical mounting, enabling the installation of power outlets into avertical column shown in FIGS. 5A, 5B and 6A˜6C, wherein the Middle Eastoutlets SMV, the French SFV outlets, the Australian SAV outlets and theUSA SUGV outlets are shown to comprise the locking convexes 15 and thestoppers 5A on the left and right surfaces of the outlet cases forattachment into vertically mounted support boxes, versus the convexes 15and stoppers 5A that are introduced at the top and bottom surfaces ofthe outlet cases for attachment into horizontally mounted intelligentboxes.

From the above explanation and the assemblies shown in FIGS. 2A˜6D it isobvious that the intelligent support boxes of the present invention arewell adapted to provide versatile, simple and low cost installation forthe many different outlets that are known as standard outlet in givencountries and regions. The intelligent support box is also made toaccommodate plug-in mechanical switches made to fit the size and shapeof the prior art wiring devices to offer many other advantages.

FIGS. 2B and 2D show the intelligent sensors 10, 10-1 and 10-2, each maycomprise an optical transceiver port, termed hereafter as optoport, orRFID antenna. Both the optoport and the RFID antenna receive a codesignal for identifying the appliance connected to the power outlet, andare further used for communicating coded command signals for operatingthe appliance.

The uniqueness of the intelligent sensors 10 are further discussed laterin connection with the block diagram of the electrical circuit, but itis obvious that the sensing tip, be it RFID antenna, a terminated end ofplastic optic fiber or an optical transceiver is introduced into asensor receptacle 10R at the rear center of the power outlet structure,shown in FIG. 3A, to reach the front surface of the outlet. The sensor10B of FIG. 8C is the shown opening of an optoport OP in FIG. 2B or theshown flat recess with no opening for the RFID tags 20B, 20U, 20A or20EU of FIGS. 7A and 7B.

It is important to note that the shown plugs and outlets with attachedRFID antenna and tag or the optoports are structured to be introduced toa three pin plug and outlet and two pin plug and outlet, using identicalRFID tag and optoport position. This is particularly important for suchplugs and outlets used in the US, EU and Mid-eastern countries havingtwo pin plugs with 19 mm pitch that can be reversely plugged and thismandate the introduction of both the RFID antenna or the optoport at thecenter of the two pin plug to be always in direct optical link and inclose proximity for the RFID communications.

The optoport OP are shown in FIGS. 7C and 7D in the center of each shownoutlet front surface as SB-OP, SUG-OP, SA˜OP, SG-OP, SF-OP and SM-OP inFIG. 7C, and the illustrated US plug and socket in FIG. 7D.

It is very important to ensure that the RFID tag and the RFID antennaare communicated from a precise position and a very close proximity toavoid reading the RFID tag by an adjacent RFID antenna, such as forexample, the adjacent outlets SU of FIG. 6A, shown as optoports, but canbe structured to employ RFID sensors.

It is clear however that the RFID tag 20U of FIG. 7A can be introducedonto the two pin US plug and into the outlets SU of FIG. 6A. Suchintroduction however has to ensure that no adjacent reading of the RFIDtag is possible. This mandate small size antenna and RFID coil and theuse of a lower frequency RFID such as 125 KHz, which is explainedfurther below.

FIG. 8A shows the inner surface of the rear cover of the intelligentsupport box 2S. The upper receptacle are shown as 2L-1 and 2L-2 forconnecting two pins 1L shown for example in FIG. 2D of the outlets SG.This is in contrast to the example of FIG. 2C showing four L1 pins asused for connecting four hybrid switches H, shown as Hn. It is obviousthat a change in the structure is the removal of two upper receptacles2L from the intelligent box 2S of FIG. 8A.

Further, the four bottom receptacles shown in FIG. 8A are divided intotwo different receptacles, two neutral power line receptacles 2N-1 and2N-2 and two ground line receptacles 2G-1 and 2G-2 linked via ground bar1G-X to dual ground line pins 1G-1 and 1G-2. The four bottom receptacles2L-1, 2L-2, 2N-1 and 2N-2 correspond precisely with the pins 1L and 1Nof any type of outlets shown above, be it SM, SMV, SG, SGV, SF, SFV,SUG, SUGV, SA, SAV, SB or SBV and any of these outlets can be introducedinto the intelligent box S2 of FIG. 8A.

The ground pins 1G-1 and 1G-2 will similarly fit each receptacle 2Gshown in FIG. 3A and the introduction by insertion of an outlet willconnect firmly the three pins of the outlet, i.e., the live line L, theneutral line N and the ground line G. The insertion of the outlet bodyinto the intelligent box will lock the body to the box via the lockingconvexes 15 into the indentations 15A and firmly hold the outlet inplace via the stoppers 5A against the indentations 5 shown in FIG. 2A.

The shown intelligent sensors 10, 10-1 and 10-2 of FIGS. 2B and 2D arepre-defined sensors such as for reading and communicating RFID oroptocode signals referred to above. As such they are preassembled andprovided as an intelligent box with a given type sensor for introducinginto outlets with OP opening shown in FIG. 7C or into outlets foraccommodating the RFID tags shown in FIG. 7A.

The intelligent support box 2S of FIG. 8A is provided withreplaceable/selectable sensors be it RFID or optoport and moreover, thesensor 10 can be replaced with a setting selector 40RS or 40RS-L formanually setting the appliance type identification for providing controland for reporting the power consumption by the identified applianceconnected to the given power outlet.

The shown openings 9-1 and 9-2 are a bayonet shaped opening for lockingthe inserted intelligent RFID sensor 41, optoport 42 or the rotarysetting selector 40RS or 40RS-L shown in FIGS. 8B˜8D.

Shown in FIG. 8B is the bayonet structure comprising PCB 60 having threerows of contacts 51, 52 and 53. The contacts 55 are shown in FIG. 8C astouching the surface of the main PCB 12 of the intelligent boxincorporating a CPU that is discussed and explained later below. Themain PCB 12 shown also to include three rows of contact 41, 42 and 43,complimentary to the rows of contacts 51, 52 and 53 with only one row ofthe three bayonet rows include the contacts 55 of FIG. 8C, such thatwhen the bayonet is rotated all the way, in the arrow 63 direction tothe stop position 62, the contacts 55 will be aligned with and touch thecorresponding PCB contacts 41, 42 or 43.

As the intelligent sensor 40 is provided as a preassembled sensor, suchas comprising the RFID sensing antenna 41, optical transceiver/sensor42, or a rotating setting selector 43, each row of the provided contacts55 is assembled into a corresponding row, such that the RFID sensor 41of FIG. 8D will engage the contact 51 of the bayonet PCB 60 and thesensor 10B inside the center cavity 10A shown in FIG. 8C will be theRFID antenna connected via the line 10C to the contacts 51.

Similar set-up is provided for the optoport sensor 42, the contacts 55are introduced into the row 52 for engaging the contact rows 42 of themain PCB 12, which provides for electrical signal communication from anoptoport transceiver 10B replacing the RFID antenna referred to above.

By this it becomes clear that it is possible to introduce into a mountedintelligent support box a selected/replaceable intelligent sensor withbayonet rotating base or other attachment (not shown) or attachingmeans, such as using self-locking convexes or a plug and socket or a pinand sensor receptacle for simple plug in attachment.

The rotating setting selector 40RS or 40RS-L shown in FIG. 8E are manualsetting selector for setting an identification to the applianceconnected to the power outlet, for reporting the power consumed and thetype of the appliance that consumes the reported power.

The shown RS contacts 53 of the bayonet PCB 60 are positioned to engagethe contacts 43 of the main PCB 12 when the bayonet bar 61 is rotatedall the way to the lock position 62, connecting the rotary selectoroutput to the CPU for identifying the appliance to be connected to thepower outlet S. The selector 40RS or 40RS-L can be set by the rotatingknob 48 prior to installing the outlet S into the intelligent box 2S ofFIG. 7A, or the rotating knob 47 can be used to be set into a given typeappliance through the opening in the front surface of the power outlet,such as shown in the OP opening in FIG. 2B or 4C.

This is provided by the longer rotary setting selector 40RS-L of FIG.8E. This enables manual setting option for the user self-setting throughthe front surface of the power outlet. FIG. 8F shows the installing ofthe bayonet sensor 40 and the rotary setting selector 40RS or 40RS-Linto the bayonet socket 9-1 and 9-2 through the inner rear cover of theintelligent support box 2S of FIG. 8F.

The setting of particulars pertaining the load or the appliance arerecited in the many referenced US patents referred to above, includingthe use of setting selector, such as the rotary selectors 40RS. Therecited particular settings of the prior art devices and the particularsettings to for the intelligent support box of the present inventionfurther provide the particulars loading of each power outlet, hybridswitch or relay installed into the box and the particulars of eachconnected appliance. The particulars are loaded into the memory 50M ofthe CPU 50 of the block diagram of the electrical circuits shown in FIG.12.

Loading addresses, locations and particulars of the loads are alsodisclosed in the referenced US patents and include loading via RFID oroptical loaders such as IR remote control unit programmed to introduceparticulars, addresses and the type of the connected appliance(s).

Other well known loading of particulars can be processed via PCs, iPadand similar devices. The loading under power however, by a loadingdevice, such as the remote control unit 160 must offer adequateinsulation for connecting a loading bayonet adaptor 149 direct intoaccesses 9 while the box is connected to the live AC line as shown inFIG. 9A.

The particulars to be loaded may include the type of the intelligent boxwhich identifies the particulars of the terminals. The box may includeautomatic pre-loading of such particular as set during the boxproduction. Regardless, FIGS. 9B and 9C illustrate the many variationsthat can be configured for the receptacles of the different intelligentbox models.

The shown differences do not reveal the whole set-up of particulars. Theshown receptacles are configured and presume outlets and hybrid switcheswill be installed to the full extent of the boxes as designed. Inpractice however it is expected that larger boxes will be installed forfuture expansion, but in practice the number of AC outlets and/or hybridswitches, mechanical switches and/or relays will not be introduced tothe box capacity.

For such short installation of hybrid switches and/or AC outlets thereis a need to update the CPU memory of the intelligent box with theactual installation on site. For such purposes, the used of the loader160 with the bayonet connector 149 is very helpful. Similar is the useof RFID or optocode loader disclosed in the U.S. Pat. Nos. 8,442,792,8,594,965 and 8,639,465.

The identifying of loads or the different appliances in a residence,office, business or other building structures can be divided into threecategories or groups. The first are the fixedly wired appliances orloads, such as lights, water boiler, ceiling fans, curtains and blindsand some types of HAVC or air conditioners that are permanently wired.

The second group of loads or appliances are the “perpetuity plugged”appliances that are plugged into a given power outlet 24 hours/7 days aweek, or all years round, such as refrigerators, coffee maker, ovens,micro wave ovens, washing machines, air conditioners, television and A/Vequipment.

The third group is the random plugged loads or appliances such as foodprocessors, Juicer or cookers, steam irons or other hand tools, personalcare appliances such as air dryers or shavers, chargers and/or PCs.

It is clear that some of the appliances in the third category or groupmay be plugged into a given power outlet “permanently” or for longperiods of time, for example a PC printer, or a “humidifier”.

The setting or sensing by the intelligent support boxes of the presentinvention provide a range of solutions that were not available in theprior art, such as the ability to introduce “fixed” solution for thelong term or permanently “plugged” appliances of the second group, suchas refrigerator or washing machine by loading their particulars via thehand loader 160 via the loading connector 149 or FIG. 9A.

The other solution for loading can be the loading via optical loaderdisclosed in the recited US patents of the prior art or via RFID loader,or direct loading by the electrical installer during the installation ofthe boxes, or by setting such particulars via the setting selectorsprovided in the rear cover of the intelligent boxes shown in FIGS. 3B˜3n.

The identifying of the randomly plugged appliances are best served bythe used of optically introduced identifier of the power plugs.Optically communicated signals are immune to noises; they are reliableand can be provided at low cost. The other practical, low costidentifiers are the RFID tags recited above and shown in FIGS. 7A˜7D.The third is the use of the rotary selector RS40-L that is accessedthrough the front of the AC outlet that can be easily reached by thedweller.

FIGS. 10B and 10C show the variation of the snap-in or the self-lockingwire terminals provided for the different intelligent support boxes ofthe present invention.

Each terminal provides for in-out or cascading connections to anotherbox, be it adjacent or a distant box, yet the cascaded boxes arecommonly installed in the same zone or room. This is due to theelectrical wiring codes and rules that are mandating individual powerlines for given load in each individual room or zone.

What is obvious with the 4H box of FIG. 10C is that only a singleneutral N and a single live L wires are needed to power four loads, suchas four lights. Each hybrid switch or a mechanical on-off switch such asshown in FIG. 14D or an SPST relay (not shown) is connected to a singleload LD terminal and each load power consumption is reportedindividually. It is also possible to power two load or more loads via asingle hybrid switch and its two snap-in terminals, each shown asLD1˜LD4. Ground terminal is a must for power outlets.

FIGS. 10A˜10C also clearly illustrate that when an AC outlet is used theload terminal is not needed and is not used. Yet a ground terminal isabsolutely required for AC outlet, for this purpose and other wiringdevices considerations at least one wire terminal can be an assignableterminal. In the example of AC outlet, the terminal that occupied theload position becomes assignable terminal for ground connection. Yet itmay be assigned to other wire connection such as separate live AC orneutral AC when the circumstances such as local codes mandate so.

The many other configurations illustrate the simplicity of the boxstructure that can be manufactured by eliminating or adding receptacles,pins, self-lock or snap-in terminals and structured current sensors madeof low ohmic metal allow shown in FIGS. 11A˜11D.

Shown in FIG. 11D is the combination of the receptacle 2LD riveted tothe self-lock or snap-in wire terminal 80LD, using rivets 80R. Similarriveting are applied to the structured current sensors R1˜R6 that areriveted to a solid brass or copper bar 83 for providing live power tothe receptacles 2L-1˜2L-6.

Not shown is the neutral brass or copper bar that feeds the poweroutlets with the neutral line via the receptacles 2N-1˜2N-n shown inFIGS. 6D and 6E. The neutral receptacles 2N are attached to the neutralbar (not shown) via rivets 80R, the same way as the live line bar 83,but without the structured low ohmic current sensors.

From the above explanation it should be clear that the many models donot require major change in molds and simple mold adjustments, known asinserts can well provide for mass production of the casing, covers,terminals, receptacles and pins needed for the mechanical constructionof intelligent support box of the present invention, all at low cost.

Moreover, it is clear that the interconnecting links between the poweroutlets, the hybrid switches, the SPDT relays and switches are solidcopper or brass bars shown in FIGS. 11A˜11C, including the ground barshown in FIG. 10A, all riveted to or supported by heavy currentreceptacles provide superior interconnections to the installed bunch ofwires inside wall box to the different switches and outlets of the priorart.

FIG. 12 is a block diagram of the electrical circuit, the CPU 50, thememory 50A and the communication circuit including the opticaltransceivers 56, the read and read write transceiver RFID antennas 55,the RF transceiver 53 including the RF antenna 54 which can be a patternor a drawn line of the PCB 12 shown in FIG. 8C.

The current sensing circuits include the amplifiers 51 and low ohmicresistors RS₁ to RS_(n), each feeds micro or mili volt level signals,developed over each resistor RS structure by the current drained throughit by a load 59.

The shown optical transceivers 56 communicate optical signals to alightguide known as plastic optical fiber or POF, which is disclosed inthe referenced US patents, publications and applications. The opticalsignal is accessed via an optical access or an optical port of an ACoutlet for propagating data pertaining current drain, power consumptionand the load or the appliance particulars.

The other way signals of the two way communications include inquiries bythe system controller and commands for operating a selected appliance.The optical transceivers can be operating in the IR wave length such as940 nm and propagate and receive IR signals in line of sight from and toand a handheld IR remote control such as disclosed in the referenced USpatents.

The block diagram of FIG. 12 is showing the power consumption reportingcircuit and the communication circuits of the preferred embodiment ofthe present invention including the CPU or analog/digital processor 50and the current signal amplifiers 51 for sensing, measuring andprocessing the current drain signal including the calculation of powerconsumed by a load 59. The load is shown as an ohmic RL, an inductanceLL and/or capacitance CL loads and combinations thereof. Thecommunication circuits include the two way buffer 52.

Electrical wiring devices, be it in buildings, including factories,warehouses, schools, public places, shops, residences, businesses andothers, are subject to a strict electrical and building codes and rules,prohibiting the connections and/or the mingling of low voltages signalsand/or power with the electrical wiring devices and/or the electricalwiring. This limits the communication circuits to communicate one of RFor optical or both.

The optical signal be it IR in line of sight, visual light or IR viaoptical cables including plastic optical fiber, known as POF can beimplemented by the circuits of the intelligent support box of thepresent invention.

The circuits of FIG. 12 are powered by a low volt and low current powersource provided by feeding AC power through high voltage AC gradecapacitors shown as C3 and C4 in FIG. 12, or to power supply circuitdisclosed in U.S. Pat. No. 8,441,824.

The VCC power source in FIG. 12 is fed via the protection resistor R2,the capacitor C3 and the diode D2 to the input or terminal of the DCregulator 58.

The regulator 58 shown is a well known analog voltage regulator ICavailable by many IC manufacturers at very low cost. The shown regulatorinput circuit includes the filter capacitor C1 for providing low rippledDC input to the regulator and a zener diode ZD1 for protecting theregulator from voltage surges, commonly affecting the electricalsystems. The output of the regulator includes a storage capacitor C2 formaintaining sufficient charge to power the intelligent support boxcircuits.

For powering the relay coil CO it is advantageous to use higher voltagessuch as 18V or 24V with limited current such as 20˜30 mA. For poweringthe latching relay coil CO it is preferred to use a short V2 pulse offor example 32V and current of about 80 mA for less than 30 mili second.For such supply of non-regulated DC power V2, the circuit shown in FIG.12 includes the protecting resistor R4, the large 275V AC ratedcapacitor C4, a rectifier diode D4, a storage capacitor C5 and aprotection zener diode ZD5 for outputting V2 to the relay coil directlyor to the latching relay coil via the driver DL of the control circuitshown in FIG. 12.

The live AC line is shown connected to the ground which is also thenegative line of the VCC and the V2 coil power line. The VCC shown is,for example, a positive 3.3V, but can be 5V or 1.8V or any voltagecommonly applied to a CPU and other ICs, including the communication ICsshown in FIG. 12.

As the live AC is connected to the negative pole of the DC supply, thepower feed into the input terminal of the voltage regulator 58 isconnected to and fed from the neutral AC line to the rectifying diode D2via the series capacitor C3 and C4, AC grade capacitors and depending onthe power line voltages, may range from, 0.1˜0.47 micro farad for the230/240 VAC (EU, UK) and up to 0.22˜0.82 micro farad for 100/120VA(Japan/US) also considering the power frequency 50 Hz or 60 Hzrespectively.

The capacitors C3 and C4 rated at 275 VAC are well known and areapproved by all known standard approving entities such as UL, VDE, JISand BS for use in electrical power circuits. The resistors R2 and R4between the capacitor C3 and the neutral AC line are protection resistorto prevent surges and/or may be a self-destructive resistor to preventfire in the remote event that a short circuit or heavy leakage willoccur.

The signal amplifier 51 is the well known linear amplifier or dualamplifiers IC, connected in series for amplifying the current drainsignal. The amplifier 51, combining two amplifiers also known asoperational amp. or op. amp., with each amp is set to amplify by, forexample, up to a factor of 100 and the two in the series can thereforeprovide up to 10,000 amplification factor.

The CPU (Central Processing Unit) or analog/digital processor 50hereafter referred to as CPU includes analog to digital and digital toanalog converter ports, digital ports and analog ports. The CPU 50 is acommonly available low cost CPU, such as 8 bit or 16 bit with low powerconsuming processor including a memory 50A. The CPU operates on 1.8V or3.3V, with an operating current such as less than 3 mA and a sleepingcurrent of few micro Amperes.

The amplified current signal is fed from the amplifier 51 to the portI/OC and based on the amplification control status and the datapertaining to the converted analog current signal to digital.

The CPU is programmed to adjust the amplification factor of theamplifier 51 via the I/O A port to obtain the optimum amplification asprogrammed, commensurate with the received signal to be in mid or mostlinear range of the sensor specified range.

As shown in FIG. 12 the load 59 is not a pure ohmic or a resistanceload, it may be a motor and/or a capacitor and/or a switching powersupply commonly used with electrical appliances including PCs. Non ohmicloads cause a shift in phase between the voltage curve and the currentcurve and/or distort the curve by high power digital switching powerloads.

FIG. 13 shows two sinusoidal curves, the voltage curve 80˜86 and thecurrent curve 90˜96, which are shifted by a random angle, caused by anunknown RL, LL, and CL load.

The voltage curve 90˜96 is curve of a reference voltage fed to the I/OVof the CPU from the neutral AC terminal via a large ohmic divider R1 andR3, with R1 value is in a range such as 0.5˜1.0 Mohm and R3 value is fewKohm, to provide an optimum reference signal level representing thepower line voltage, the 120V/60 Hz of the US or the 230V/50 Hz of theEuropean power line. The current curve 90˜96 is the amplified currentsignal and an accurate reference of the current drain value.

A zero crossing 80 of the reference voltage curve is the start positionor point in time for the processing of power consumption reading. Thecurrent phase shift is evident from the deviation of the zero crossingof the current curve.

The zero crossing 80 shown is the cross from negative to positive, atthat same time, the start position time 90, the current curve is shownto be close to the peak of the negative curve, or at a phase shift ofmore than 90°.

The processing shown in FIG. 13 is the measuring of the five referencecycles 81˜85 and the phase shifted five current cycles 91˜95. Themeasuring positions or points in time are shown in FIG. 13 as ten pointsrandomly spread over the voltage curve as 81-1, 82-1, 83-2, 84-3 and85-4 for the voltage points of time, with the exact point of times overthe current curve shown as 92-4, 93-5, 94-6 and 95-8. The end ofprocessing positions or point of times is shown as 86 and 96. The showntime interval is 2 mSec for 50 Hz and 16.6 mSec for 60 Hz. The verticallines divide one cycle into ten points of time, therefore the intervalbetween each point of time is the time duration of one cycle divided by10.

The time interval or the number of measure points during one cycle (Hz)directly relates to the accuracy of the measurement, same applies to thenumber of measured AC cycles in one measuring round. Both are a decisionto be made, in which higher accuracy require more measured AC cycles(Hz) in one measuring round and a decrease in time intervals or anincrease in the number of measuring point.

The power consumption is the product of a calculated sinusoidal V×Agraphs created on the basis of the measured values at each point of timesimultaneously and summed up per each cycle on the basis of the voltagereferenced timing. The shown five cycles 81˜85 in FIG. 8 are an exampleof one round of measurement repeated, for example, every two seconds.When a calculation round is programmed to be carried every two secondsthe total of five measured cycles will be multiplied by a factor of 20for 50 Hz and 24 for 60 Hz (50:5/sec.×2 sec.) or (60:5/sec.×2 sec.).This will represent the power consumed in two seconds.

By the above it should be obvious that the power consumption calculationby the current sensors of the present invention can be simplified andperformed by a low cost Central Processing Unit (CPU) or ananalog/digital processor both are available from many IC manufacturers.It should be also obvious that the current sensor of the presentinvention can be made small in size and provide accurate, practical andlow cost solution to the power consumption reporting.

The calculated power consumed values are stored and updated in thememory 50A included in the CPU 50 for reporting as programmed to acontroller. The calculated power consumption value is converted into apredefined programmed protocol that includes particulars of the load orappliance and the location of load and/or of the AC outlet. The storedand updated data in the memory are coded protocols.

The referenced patents, publications and application, particularly theU.S. Pat. No. 8,170,722 discloses the coding of power consumptionprotocols and the signal structure of the protocol reporting. Thecommand structure is designed to be short command comprising five bytesonly that include all the necessary data for reporting powerconsumption, the load particulars and its location.

The RF transmitter output measured commonly in micro watt units, doesnot consume much power, however, it is preferable to minimize the lengthof the reporting protocols. When any of the shown transceivers, the RF53, the RFID 55 and the optical 56 are not needed they are not used. RFoperating systems may not include the optical transceiver 56, systemsoperating through optical network may not include the RF transceiver 53and/or the RFID antennas. Regardless it is possible to include all thecircuits and operate wireless, RFID and optical network in parallel oras programmed.

Moreover, the optical network of POF mandates the introduction ofplurality of optical transceivers for propagating the optical signal incascade in concert with the optical communications between support boxesand between the support boxes with the power outlets, all being cascadedcommunications of the optical network of the system as shown in FIG. 15.

The two way buffer 52 is a well known amplifier-buffer, available insmall surface mounted IC packages from many semiconductor manufacturers.Its purpose is to interface the signals and their levels and feed thetwo way signals between the transceivers 53 and 56 to the CPU 50 I/O Tand I/O R ports. Depending on the selected CPU and the analog/digitalprocessor 50 there are many such devices that include I/O ports thatrequire no additional buffer as they can be programmed to output andreceive varying signals commensurate with the signal exchanged betweenthe CPU and the transceivers. For such devices the two way buffer 52 isnot needed and is not used.

The reporting of power consumption to a controller directly or via anetwork device, such as a current data receiver that receive RF signalsor optical signals via an optical cable, must include identifying data.The data should include an identification of the load 59 or theappliance or the type of or the family of the appliance.

The data should further include the location of the appliance within thepremise, be it an apartment, or a shop, or a school, or a factory. It ispreferred that the data includes the specific identification of the ACoutlet, or to which current receiver the outlet is connected orreporting to.

FIGS. 14A and 14B show the SPDT hybrid switch-relay combination in whichFIG. 14A is a cut view of the hybrid combination of relay coil 152magnetically pulling an SPDT pole 116 attached to an armature 143 on oneend of a base or a body 130. The other end of the body 130 is a base foran SPDT micro switch pole 114 activated by mechanical plunger 102 tocompress the springy structure of the pole 114.

The two “contactors” 110 and 111, as defined in the U.S. patentapplication Ser. Nos. 14/045,877, 14/093,966 and 14/143,133, link thepole terminals 1L and 1LD via the pole contacts 115 via the contacts 112and 113. As disclosed in the referenced application dated Oct. 4, 2013,Dec. 9, 2013 and Dec. 30, 2013 respectively, the switching on-off statusor connect-disconnect status can be reversed by the micro switch plunger102 manually or remotely via the relay armature 143 by applying power tothe relay coil independently from the manual plunger status or position.

FIG. 14A shows a straight elongated structure of the combined hybridswitch relay with the plunger on one end and the relay coil 152 on theother end. FIG. 14B shows the micro switch pole 114 mounted onto a baseor body 131 side by side with the pole 115 linked by the contacts 112,113 and 115 via perpendicular contactors 110 and 111.

The side by side shortened the length of the hybrid combination into asize for assembly into a casing 140, have a size that conveniently fitsthe present day manual switches size, as used in the many countries ofthe world including the US and Japan, using a short, small sizesswitches and outlets.

The structure shown in FIG. 14B introduced two more practicaladvantages, the first is the moving of the plunger 102 toward the centerof the casing 140 and the other is the introduction of a mechanicallatching push key 100. The latching push key is disclosed in the abovereference to US patent applications, based on known technics andstructures, and therefore it is not necessary to fully disclose it here.Mechanical latching devices are known, for example, one can view acabinet door latching device that is locked (latched) or released (open)as a larger example of a very small latching device 15D shown in FIGS.14B (partially) and 14E. The structures and the details of the latchingmechanism are fully disclosed in the referenced US applications.

Another very well known example is the mechanical latching of a ballpoint pen that is pushed by a push rod or button into writing positionand re-pushed or depressed to a release position, so it can be insertedinto a shirt pocket without leaving ink mark.

There are two ways to latch the hybrid switch-relay status, one isexplained above using the latching key 100 disclosed in the abovereferenced application, the other is to latch the relay pole 116 usingthe small latching structure 150. In such case the action to releaselatched pole must be provided, be it by re-applying power to the relaycoil by re-pushing the mechanical switch key. This is discussed below,however when the latching is applied to the relay pole 116, the key 100should no longer be used and a non-latching push key 100A is usedinstead.

FIG. 14C shows dual micro switch poles 114-1 and 114-2 with contact115-1 and 115-2 and a relay pole 116D mounted onto a base or body 133and linked via dual reversing contactors, using three sets of contacts112-1˜112-3 and 113-1 to 113-3 (not clearly visible), such that the dualsize plunger 103 can manually engage the dual micro switch poles toreverse the polarity of the connected traveler T1 and T2 through thepole 116D of the relay or reverse the pole 116D of the relay to reversethe terminal LD (load terminal) to switch-over from one traveler to theother.

The US patent applications referred to above, fully disclose thereversing and non-reversing DPDT relay-switch combinations andoperations, actuated manually via a plunger for operating dual polemicro switch or via a rocker switch, similar to the disclosed actuationsfor the hybrid SPDT switches, be it via micro switch plunger or via arocker manual switch structure. Both micro switches and rocker switchesare well known and need no further detailed explanations.

The relay coil 151 is operated by applying power to the coil to attractthe armature and the pole 116D shown in FIG. 14C, the same way the coil152 of FIG. 14A is operated, for reversing the T1-T2 connection with theload terminal LD of FIG. 14C.

Further, the US applications referred to above also disclosenon-reversing DPDT hybrid switch and relay for use in humid environment,such as in bath rooms and similar locations for connecting ordisconnecting both the AC live line L and the AC neutral line N from thepower lines.

Even though the self-locking terminals and the receptacles shown inFIGS. 2A to 12 do not show specifically the terminals for introducing aDPDT or reversing DPDT hybrid switch or hybrid switch and relay,receptacles and/or self-locking wire terminals can be introduced intothe intelligent support boxes of the present invention, and moreover,any size of such hybrid switches or hybrid switch-relay and/ormechanical switch and/or outlet with or without sensor 40 and/or relaycan be accommodated, be it single pole, dual poles or multi poles.

The shown DPDT reversing hybrid switch-relay in FIG. 14C is packaged orencapsulated into an enclosure 141, having a latching key 100 forengaging the plunger 103, including the shown traveler terminals T1 andT2, the load terminal LD and an indicator optical access 160 forintroduction into the intelligent support boxes of the presentinvention.

It is clear and obvious that a reversing mechanical switch, known asfour way switch can be structured in the same enclosure 141 with similarpush to reverse key or rocker key or any other practical known key, andbe introduced into the intelligent support box of the present inventionfor reversing the polarity of the T1 and T2 traveler connectionsmanually.

It is also clear and obvious that a non-reversing DPDT hybridswitch-relay can be structured and introduced into the intelligentsupport box of the present invention, the same way as described abovefor all the other wiring devices including the SPST hybrid switches.

FIG. 14D shows the well known micro switch structured for introductioninto the intelligent support box as one type switch for operating a loadmanually, with no remote operating provisions, a simple manual on-offswitch. The shown contact 112 is a dummy contact for providing stopmovement to the pole 114.

The key 100 however is providing the latching for the switch, such thatthe micro switch can be switched on and off by push-push action.

The hybrid switch of FIG. 14E is disclosed in the U.S. application Ser.No. 14/143,133 referred to above. The hybrid switch of FIG. 14E does notuse a relay pole or contactors. FIG. 14E shows a basic SPST action by apair of contacts, the fixed contact 111 attached through the body 134 tothe load pin 1LD. The moving contact 112 is the contact of the switchpole 114 that connects to the AC live via pin 1L.

The pole 114 is shown to be operated by the armature 143 activated bythe magnetic pull of the coil 151. The power applied to the coil duringa short time, such as 10-30 mili sec. is sufficient to engage thecontacts 111 and 112 and latch the pole by the latching device 150. Thelatching device 150 latches the pole to the base or the body 134 of thehybrid switch assembly. Reapplying the short power pulse to the coil 151will re-attract the armature 143 and release the latching state of thepole 114 and disconnect the engagement of the two contacts 111 and 112,thereby reversing or switching off the hybrid switch state, ordisconnecting the power fed through the pin 1L to the load pin 1LD.

The hybrid-switch uses a non-latching key 100A that is used to push thearmature 143 into latching or release independently from the coil actionthat is driving the armature 143 by the magnetic pull that does the samething. This introduced many advantages to the electric systems.

The hybrid switch does not consume continuous relay power beyond the fewmili seconds, it does not generate heat, it offers low cost solution toproduce the hybrid switch and does not add any costs in assembling andinstalling the hybrid switch into electrical boxes of the prior art andit is providing the simplest installation for automation of theelectrical in factories, hospitals, residences, businesses, publicbuilding and the many other buildings having electrical system for lightand power other machines and appliances.

FIG. 15 illustrates and shows how simple is the electric systeminterconnection using the present invention is for a whole residencehaving two bedrooms, living room, dining room, kitchen, bathroom andentrance/corridor spaces.

This is a typical apartment size of some 100˜120 square meter (900˜1200ft). Such size apartment commonly uses a total of 14˜16 light switchesand some 25˜30 outlets.

The shown system of FIG. 15 comprising 30 outlets S and 16 hybridswitches H, installed into 19 intelligent support boxes 2H, 2S, 1H+S, 3Hand 3S. The shown POF 99 is estimated to be in length of less than 100meter (300 ft) and the shown cascading twisted pair is estimated to beless than 50 m or 150 ft.

The automation control and reporting devices connected in the cascadedtwist pair lines include four command converters and power consumptionreceivers 93, two keypad 96 for remote operation, one touch pad 96A anda single relay station/adjustable IR repeater 97, for operating the AVappliances, lights, air conditioner, water boiler and any other remotelycontrolled electrical devices and appliances in the residence.

The shown electrical wiring connections in FIG. 15 are a fraction of theconnections needed and/or applied to the prior art for electricalsystems. Particularly those that are introducing automation devices forresidences. Moreover, the number of the connection points for theelectrical wires L, N and G of the shown system in FIG. 15 are far less,they are a fraction of the connections made in today's new residences,even for system using no remote operation or automation of any kind.

It should be obvious from all the above that the intelligent supportboxes of the present invention is an epoch making innovation in theelectric wiring field. The intelligent support boxes together with thehybrid switches and outlets, all automated and reporting/identifyingfull details pertaining the power consumed through each outlet andswitch. The new system offers a new horizon for the smart power gridthat was awaiting in limbo for the revisit of the present day'selectrical systems created during the Edison era.

It should be understood, of course, that the foregoing disclosurerelates to only a preferred embodiment of the invention and that it isintended to cover all changes and modifications of the example of theinvention herein chosen for the purpose of the disclosure, whichmodifications do not constitute departures from the scope of theinvention.

What is claimed is:
 1. A method for setting at least one of homeautomation grid and network structurally integrated with an electricalgrid of one of a residential and a commercial unit via a plurality ofintelligent support boxes, each connects to said electrical grid directand to at least one load via at least one electrical wiring device, saidplurality of intelligent control boxes are linked to at least one of acontroller and a command converter by one of bidirectional opticalsignals via one of cascading grid of optical cable and at least one ofwireless RF and IR signals bidirectionally propagated in open air; saidintelligent support box comprising a CPU, at least one of settingselector and a memory for said setting and for loading particulars data,circuits for operating and for calculating the power consumed by eachload via each said wiring device and communication circuits forcommunicating at least one way of bidirectional signal with said one ofcontroller and command converter via one of said home automation gridand network, said method comprising the steps of: a. loading saidparticulars data pertaining to each installed intelligent support box asstructured including data pertaining to said at least one wiring deviceinto said memory via said communication circuit; b. setting one ofidentifying numeral and one of a code and address for identifying theinstalled location within said unit of each of said intelligent supportboxes by one of said setting selectors and via said controller orwirelessly via one of an hand held loader and a pad; c. recording intosaid memory and via said communication circuit and said one of homeautomation grid and network into at least one of a memory included insaid one of controller and command converter the stored particulars andthe identified installed location within said unit; and d. identifyingeach load powered by each said wiring device via one of said settingselectors and a given load identifier stored in the memory of said oneof controller and command converter or via one of said hand held loaderand a power plug with one of an optical port and an RFID tag mated witha reciprocal optical port and RFID reader respectively accessed via apower outlet of said wiring device attached to said intelligent supportbox.
 2. The method according to claim 1 wherein said grid is one of alow voltage bus-line for propagating electrical signal and an opticalgrid for propagating at least one of said optical signals via saidoptical cable including IR signal propagated in line of sight in saidopen air, said network including propagation of signals comprising saidoptical signals via said optical cable and said IR signals in line ofsight, said electrical signals via bus line, said RF signals andcombinations thereof; and said controller is selected from a groupcomprising a video interphone monitor, a shopping terminal, a dedicatedhome automation controller, an home automation grid distributor, a keypad, a touch pad, hand held controller and combinations thereof.
 3. Themethod according to claim 2 wherein said optical signal and electricalsignal are converted two way for interfacing the propagated opticalsignal with electric signal and electrical signal with optical signalvia one of said command converter and automation grid distributor, andwherein said RF signal and said optical signals are converted two wayfor interfacing said RF signal with optical signals and said opticalsignals with RF signals via at least one of said automation griddistributor and said intelligent support box for exchanging signalscommensurate with command and response signals of a given load via saidautomation grid.
 4. The method according to claim 1 wherein saidbidirectional signals comprising an operate commands for on-offswitching and operating at least one given load powered by at least onegiven electrical wiring device and responses for providing said one ofcontroller and command converter with at least one of data pertainingthe status of and one of the current drawn and the power consumed bysaid at least one given load.
 5. The method according to claim 4 whereina combination of said particulars of a given load powered by a givenelectrical wiring device, said one of installed location and one of codeand address, said operate commands and responses are integrated intointegrated control commands stored in said memory and a memory of atleast one of said controller and command converter for storing theintegrated control commands during the initial setup of the system andupgrade via the controller at random, enabling the propagating of shortrecall of operate commands and responses via said grid and network andoperate said given function of said given load in the given location viaa single integrated command and a single integrated response.
 6. Themethod according to claim 5 wherein a specific load powered via saidintelligent support box is communicating via one of said RF signal inopen air and via one of said optical signal through said optical portand IR in line of sight wherein said specific load is responsive to aspecific commands and responses only and, wherein said memory and saidmemory of said controller and said command converter are updated toinclude said specific commands and responses and the intelligent supportbox is further set via said controller to communicate said specificcommands and responses with said specific load.
 7. Said method accordingto claim 5 wherein variety of loads powered via said intelligent supportbox are communicating via one of said RF signal in open air and via oneof said optical signal through said optical port and in line of sightwherein said variety of loads are responsive to diverse commands andresponses and wherein said memory and said memory of said controller andsaid command converter are updated to include said diverse commands andresponses and the intelligent support box is further set via saidcontroller to communicate with each of said variety of loads onlydiverse commands and responses, each commensurate with each one of saidvariety of loads.
 8. The method according to claim 1 wherein saidintelligent support boxes comprising horizontally oriented boxesdiversified in size and capacity and vertically oriented boxesdiversified in size and capacity for supporting said electrical wiringdevices selected from a group comprising manual switches, hybridswitches, relays, power outlets, power sockets and combinations thereof.9. The method according to claim 8 wherein said intelligent support boxis structured to switch on-off a load directly connected to one of anattached manual switch and an hybrid switch including the switchingon-off of a load powered via a given power outlet jointly attached tosaid intelligent support box for powering a load.
 10. The methodaccording to claim 1 wherein said residential and commercial unit isselected from a group comprising a single home, an apartment of abuilding, one of a room and suit of an hotel, a shop, a restaurant, aclub, a given area of a warehouse, an office, a garage, a workshop, oneof a class and classes of a school, a library, one of a room and roomsof an hospital, at least one of a room and rooms of a public building,and at least one of area and a zone of a factory.
 11. A structurallyintegrated electrical grid of one of a residential and a commercial unitwith at least one of home automation grid and network via plurality ofintelligent support boxes each connects to said electrical grid directand to at least one load via at least one electrical wiring device, saidintelligent control boxes are linked to at least one of a controller anda command converter by one of bidirectional optical signals via one ofcascading grid of optical cable and at least one of wireless RF and IRsignals bidirectionally propagated in open air; each of said intelligentsupport boxes comprising a CPU, at least one of setting selector and amemory for setting the home automation grid and for loading particularsdata pertaining to each installed intelligent support box as structuredincluding data pertaining to said at least one wiring device, circuitsfor operating and for calculating the power consumed by each load viasaid wiring device and communication circuits for communicating at leastone way of bidirectional signal with said at least one of controller andcommand converter via one of said home automation grid and network; eachof said intelligent support box is structured and set to attach at leastone of a given wiring devices and is one of preloaded and randomlyloaded with said particulars and further comprising a structured currentdrain sensor for each attached wiring device for said power consumedcalculation, said setting including one of an identifying numeral andone of a code and address via said at least one of setting selector orwirelessly via one of an hand held loader and a pad for loading a boxidentifier to said memory and to the memory of said at least onecontroller and command converter for recording and identifying each ofsaid intelligent support boxes and their installed location within saidunit; and each given load powered via said given wiring device isidentified via one of said setting selector and a given load identifierstored in said memory and in the memory of said one of controller andcommand converter or via one of said hand loader and a power plug withone of optical port and an RFID tag mated with a reciprocal optical portand an RFID reader respectively accessed via a power outlet of saidwiring devices attached to said intelligent support box.
 12. Thestructurally integrated electrical grid according to claim 11 whereinsaid grid is one of a low voltage bus-line for propagating electricalsignal and an optical grid for propagating at least one of said opticalsignals via said optical cable including IR signal propagated in line ofsight in said open air, said network including propagation of signalscomprising said optical signals via said optical cable and said IRsignals in line of sight, said electrical signals via bus line, said RFsignals and combinations thereof; and said controller is selected from agroup comprising a video interphone monitor, a shopping terminal, adedicated home automation controller, an home automation griddistributor, a key pad, a touch pad, hand held controller andcombinations thereof.
 13. The structurally integrated electrical gridaccording to claim 12 wherein said optical signal and electrical signalare converted two way for interfacing the propagated optical signal withelectric signal and electrical signal with optical signal via one ofsaid command converter and an automation grid distributor, and whereinsaid RF signal and said optical signals are converted two way forinterfacing said RF signal with optical signals and said optical signalswith RF signals via at least one of said automation grid distributor andsaid intelligent support box for exchanging signals commensurate withcommand and response signals of a given load via said automation grid.14. The structurally integrated electrical grid according to claim 11wherein said bidirectional signals comprising an operate commands foron-off switching and operating at least one given load powered by atleast one given electrical wiring device and responses for providingsaid one of controller and command converter with at least one of datapertaining the status of and one of the current drawn and the powerconsumed by said at least one given load.
 15. The structurallyintegrated electrical grid according to claim 14 wherein a combinationof said particulars of a given load powered by a given electrical wiringdevice, said one of installed location and one of code and address, saidoperate commands and responses are integrated into integrated controlcommands stored in said memory and a memory of at least one of saidcontroller and command converter for storing the integrated controlcommands during the initial setup of the system and upgrade via thecontroller at random, enabling the propagating of short recall ofoperate commands and responses via said grid and network and operatesaid given function of said given load in the given location via asingle integrated command and a single integrated response.
 16. Thestructurally integrated electrical grid according to claim 15 wherein aspecific load powered via said intelligent support box is communicatingvia one of said RF signal in open air and via one of said optical signalthrough said optical port and IR in line of sight wherein said specificload is responsive to a specific commands and responses only and,wherein said memory and said memory of said controller and said commandconverter are updated to include said specific commands and responsesand the intelligent support box is further set via said controller tocommunicate said specific commands and responses with said specificload.
 17. Said structurally integrated electrical grid according toclaim 15 wherein variety of loads powered via said intelligent supportbox are communicating via one of said RF signal in open air and via oneof said optical signal through said optical port and in line of sightwherein said variety of loads are responsive to diverse commands andresponses and wherein said memory and said memory of said controller andsaid command converter are updated to include said diverse commands andresponses and the intelligent support box is further set via saidcontroller to communicate with each of said variety of loads onlydiverse commands and responses, each commensurate with each one of saidvariety of loads.
 18. The structurally integrated electrical gridaccording to claim 11 wherein said intelligent support boxes comprisinghorizontally oriented boxes diversified in size and capacity andvertically oriented boxes diversified in size and capacity forsupporting said electrical wiring devices selected from a groupcomprising manual switches, hybrid switches, relays, power outlets,power sockets and combinations thereof.
 19. The structurally integratedelectrical grid according to claim 18 wherein said intelligent supportbox is structured to switch on-off a load directly connected to one ofan attached manual switch and an hybrid switch including the switchingon-off of a load powered via a given power outlet jointly attached tosaid intelligent support box for powering a load.
 20. The structurallyintegrated electrical grid according to claim 11 wherein saidresidential and commercial unit is selected from a group comprising asingle home, an apartment of a building, one of a room and suit of anhotel, a shop, a restaurant, a club, a given area of a warehouse, anoffice, a garage, a workshop, one of a class and classes of a school, alibrary, one of a room and rooms of an hospital, at least one of a roomand rooms of a public building, and at least one of area and a zone of afactory.